Ankle Foot Orthosis Tri-Planar Control Composite Design
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Solution Overview
Problem
Traditional ankle foot orthoses (AFOs) and leather gauntlets lack adjustability, durability, and comfort, providing insufficient tri-planar control and stability for conditions like Posterior Tibial Tendon Dysfunction (PTTD) and ankle arthritis.
Innovation Solution
An AFO design combining a closed cell polyethylene foam inner lining with polyolefin elastomeric material and key structural thermoplastic components, featuring a medial stirrup-like configuration and adjustable closure mechanisms, to provide improved support, flexibility, and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rigid plastic AFO design is used, then structural support is provided, but comfort and flexibility are reduced
Solution Approach 1:
The AFO combines multiple materials with different properties: rigid thermoplastic components (polypropylene or polyethylene) for structural support, closed-cell foam for cushioning and comfort, and flexible materials (neoprene or elastic fabric) for adaptability. This composite structure allows the device to simultaneously provide strength and comfort through material property integration.
Solution Approach 2:
Different regions of the AFO use different material compositions and densities. The rigid thermoplastic is concentrated in load-bearing areas like the shin guard and ankle support, while softer foam and flexible materials are used in contact areas with the skin. This localized material distribution optimizes both structural support and comfort.
2Ease of operation
If traditional leather gauntlet design is used, then comfort and flexibility are improved, but durability and ease of cleaning are reduced
Solution Approach 1:
The AFO replaces traditional leather with a composite structure where synthetic flexible materials (neoprene or elastic fabric) provide the comfortable interface with the skin, while rigid thermoplastic components provide durability. The closed-cell foam layer provides water resistance and ease of cleaning. This composite approach maintains comfort while improving durability and hygiene.
Solution Approach 2:
The closed-cell foam material provides a non-porous surface that resists water absorption and is easy to clean, replacing the porous structure of traditional leather. This material property improvement enhances durability and ease of maintenance while maintaining flexibility and comfort through the foam's inherent properties.
3Ease of manufacture
If traditional AFO design is used, then manufacturing simplicity is maintained, but adjustability and customization are reduced
Solution Approach 1:
The AFO is divided into separate modular components: rigid thermoplastic pieces, closed-cell foam sections, and flexible material layers. These segments can be independently adjusted, removed, or replaced to customize the device for different patient needs while maintaining relatively simple manufacturing processes for each component.
Solution Approach 2:
The AFO incorporates adjustable elements such as flexible materials that can be stretched or compressed, and modular components that can be repositioned. This dynamic design allows the device to adapt to different patient anatomies and conditions without requiring complex manufacturing processes.
4Stability of the object's composition
If more rigid materials are used to improve stability, then control is enhanced, but comfort and flexibility are reduced
Solution Approach 1:
The AFO uses rigid thermoplastic materials (polypropylene or polyethylene) for stability and control in structural components, while combining them with soft closed-cell foam and flexible materials (neoprene or elastic fabric) for comfort. This composite approach allows simultaneous achievement of stability and comfort through material property integration.
Solution Approach 2:
Rigid thermoplastic materials are strategically placed in areas requiring stability and control (shin guard, ankle support), while softer foam and flexible materials are used in areas contacting the skin. This localized material distribution provides stability where needed while maintaining comfort in contact areas.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The AFO offers enhanced tri-planar control and stability, is hygienic, waterproof, and adjustable, providing better fit and durability than traditional devices, addressing the limitations of existing AFOs and leather gauntlets.
Implementation Method 1
a closed cell polyethylene foam inner lining
Implementation Method 2
simplified thermoplastic orthosis designs
Data Source
AI summary
The present disclosure provides a custom or pre-fabricated ankle foot orthosis providing tri-planar control of the ankle foot structure. The ankle foot orthosis comprises a brace body composed of reinforcement strips and a closure mechanism.